Download - Milling Process

AS PREPARED BY:

TIMOTHY GALISIN

01BEHS-201005-00108

EHS 4163

INDUSTRIAL HEALTH & SAFETY 2

Milling Process

Introduction
Milling is the most common form of machining, a material removal process, which can create a variety of features on a part by cutting away the unwanted material. Milling is typically used to produce parts that are not axially symmetric and have many features, such as holes, slots, pockets, and even three dimensional surface contours. Parts that are fabricated completely through milling often include components that are used in limited quantities, perhaps for prototypes.

Types of Milling Machines

Factors that determine the finish required on machined material by Milling machine

material to be machined;

type of cutter;

finish required;

depth of cut;

rigidity of machine and work piece.

Hazards Identification and Health Effects in Milling Processes
HAZARDHEALTH EFFECTSCONTROL MEASURESFlying metal debris(Safety Hazard) Laceration (open wound) Secure guards in place before operation of machine.Pay full attention to the work task.Wear eye protection at all timesContact with coolant fluid(Safety Hazard)(Health Hazard)Irritation of skin and eyesInjury from slip and fallClean-up at all times to prevent slips and fall.Wash hands to clean away any coolant in contact with skin.If coolant splashed to eye, wash away as soon as possible to reduce irritation to eyes.Caught at nip points of machine(Safety Hazard) LacerationRemove any jewelry, watches and rings. Keep long hair tied up.Ensure guards are in place before work task

HAZARDHEALTH EFFECTSCONTROL MEASURESChanging tool bit on machine(Safety Hazard) Finger or hand lacerationFoot injury if tool bit dropped Wait until CNC Mill machining operation stops.Wear recommended glovesEnsure tool bit is secure and properly captured in place.Wear recommended footwearCutter of milling machine slip out(Safety Hazard)Injury if struck operatorEnsure the cutter is tightly locked on device before operationHot machined parts or surfaces of machine(Safety Hazard) Burns from handling themEnsure the machine and the machined material has cooled down Avoid touching the surfaces of machine or machined parts while still hot to touch

HAZARDHEALTH EFFECTSCONTROL MEASURESLoose clamped parts flying off(Safety Hazard) Injury on impact with operator Check that work piece is clamped tight Conduct training for workers Implement safe work procedures Provide and use appropriate safety footwearExcessive noise exposure from machine(Health Hazard) Hearing LossApply acoustic damping material in the enclosure of the CNC machine to control the noise level Conduct regular noise monitoring Conduct regular audiometric tests for exposed Provide and use appropriate hearing protection

HAZARDHEALTH EFFECTSCONTROL MEASURESRemoval of stock material from machine(Safety Hazard) CutsEnsure the machine has stop and powered down sufficiently.Do not let the cutter cut into material to stop it.Visual inspection of cutter(Safety Hazard) Injury from cutter if shattered and debris ricochet (projectile rebound) in contact with a running cutter. When setting up to work, check the milling cutter.Make certain all loose hand tools, spindle wrenches, chuck keys, and measuring tools have been removed from the machine and put in the proper location.

References
http://safety.uncc.edu/sites/safety.uncc.edu/files/Operating_A_Milling_Machine.pdf , UNC Charlotte Environmental Health and Safety Office (accessed on 23 Apr 2013)http://www.ccohs.ca/oshanswers/safety_haz/metalworking/millingmachines.html, Canadian Centre for Occupational Health and Safety (accessed on 23 Apr 2013)http://www.mfg.mtu.edu/marc/primers/milling/millmach.html (accessed on 25 Apr 2013)http://www.liv.ac.uk/safety/work_area_hazards/workshops/milling_machines/, University of Liverpool Health & Safety (accessed on 25 Apr 2013)http://www.custompartnet.com/wu/milling (accessed on 25 Apr 2013)http://www.youtube.com/watch?v=Ucey6iFKxeQhttp://www.youtube.com/watch?v=bndrA18E4jw